Manifold Assembly for Delivery of Fracture Fluid

ABSTRACT

Disclosed is a flanged manifold frack delivery system, or manifold assembly, for distributing fluids to a well wherein the assembly comprises at least one high pressure output studded or flanged connection in the absence of rubber seals. The high-pressure connection consists of cross-blocks and spools connected in series to each other. Described is a combination of high and low-pressure conduit configurations disposed along the length of the chassis; the high-pressure conduit assembly is made up using studded or flanged iron connections terminating at the opposite end to the low-pressure inlet with a studded or flanged iron connection so that a spool can be attached at the height of the well head to route the fluid to the well head. The assembly may be pre-fabricated to the user&#39;s needs and assembled on site, or may be mobile and delivered to the desired site for use.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Nonprovisional applicationSer. No. 17/030,807 filed 24 Sep. 2020, which is a continuation of U.S.Nonprovisional application Ser. No. 16/438,065 filed 11 Jun. 2019—nowissued as U.S. Pat. No. 10,808,512 on 20 Oct. 2020, which claimspriority to U.S. Provisional Application No. 62/685,114 filed 14 Jun.2018, each of which are incorporated herein by reference in theirentireties.

FIELD OF THE DISCLOSURE

This subject matter of the present disclosure relates to fluid deliverysystems, and in particular to a manifold fracture delivery system fordelivery of fluids under high-pressure.

BACKGROUND OF THE DISCLOSURE

Hydraulic fracturing, or “fracking,” is the process of injecting a fluidinto a wellbore at high pressure to fracture rock formations andfacilitate release of trapped hydrocarbons within the formation.Fracking operations typically use manifold trailers or trailer-mountedskids that have a piping system attached thereon to deliver thepressurized fluids to the wellhead at surface.

During fracking operations, for example, a blender initially mixes thechemicals, proppant (e.g., sand), and carrier fluid for the frackingoperation into a slurry. A low-pressure side of the piping systemreceives the slurry from the blender at a low pressure and routes theslurry to a manifold skid or trailer. From the skid or trailer, theslurry is distributed to a plurality of pumps, which pressurize theslurry to a high-pressure—e.g., up to about 20,000 psi. The pumps returnthe pressurized slurry to a high-pressure side of the manifold skid ortrailer, which then routes the pressurized slurry to the wellhead.

As an example, US 2013/0284455 is directed to a delivery system forfracture applications. US 2014/0231554 is directed to a manifold trailerwith multiple articulating arm assemblies. U.S. Pat. No. 8,474,521 isdirected to an adjustable modular skid system for manifolds with aplurality of skid modules having a frame to support oil field fluidcomponents.

Conventional manifold skids or trailers include multiple high-pressurepiping systems that have multiple discharge points. Rigging up theconventional manifold skid or trailer can require operators to assemblehigh-pressure flowline iron known as integral iron, which includespiping components, such as tubular connectors, tubular swivelconnectors, valves, and piping joints between the manifold skid ortrailer and the pumps. These elements couple with other pipingpreinstalled in parallel along the length of the manifold skid ortrailer. The high-pressure flowline integral iron is stackedhorizontally and vertically on the manifold skid or trailer to formmultiple manifolds.

High-pressure fluid flowing through the high-pressure flowline integraliron can cause the piping components to expand and hammer, which maycause binding and/or failure of one or more of the integral connectionsbetween the piping components. Further, the high-pressure fluid flowingthrough the high-pressure flowline integral iron may pulsate and hammer,which causes vibrations that may induce cracks or failures andcontribute to a safety hazard to personnel in one or more of theintegral connections between piping components and/or the pipingcomponents themselves in the event of failure. Finally, in the case of acomponent replacement, rig up time and complexity is increasedsignificantly due to the numerous connections between the various pipingcomponents of the high-pressure flowline integral iron.

As an example, FIG. 1A is a perspective view of a typical manifold skidor trailer 10 according to the prior art as used within the industry.The typical manifold trailer 10 has a base 12 having a rack 14 on whichmultiple conduits 30 a-b and 40 a-b are supported. Headers 20 a-b havemultiple low-pressure fluid inlets 22 for connection to a source offluid (e.g., fracture slurry). The headers 20 a-b connect tolow-pressure conduits 30 a-b that run along the length of the rack 14.Often, and as shown here, two low pressure conduits 30 a-b run parallelto one another above two high-pressure conduits 40 a-b, which also runalong the rack 14. The low-pressure conduits 30 a-b have a series of lowpressure outlets 32 to connect to inlets of external pumps (not shown).The low-pressure outlets 32 typically have 1502 wing-type connections orsimilar.

On the high-pressure side, each of the outlets of the external pumps(not shown) connect into the high-pressure conduits 40 a-b via an inletassembly 50, which is shown in closer detail in FIG. 1B. Ends of thehigh-pressure conduits 40 a-b have connections 42, which can be 1502wing-type connections or similar for connecting to downstreamcomponents, such as wellhead connections, conduits on another manifoldtrailer, etc. The inlet assemblies 50 has piping made up of a series ofconnections 52 a-c (e.g., 1502 wing type connections or similar) withswivels 54 to allow for movement of the inlet assemblies 50. All of theconnections for the swivels 54 and for the 1502 wing type connections42, 52 a-c have elastomers and gaskets that are prone to leaking andfailure.

FIG. 1B is a close-up perspective view of FIG. 1A, illustrating ahigh-pressure inlet assembly 50. The high-pressure conduit 40 hasbranched inlet piping 45 from the conduit 40. The swivel 54 connects tothe branched piping 45 via connections 54 a, such as 1502 wing typeconnections or similar, and the swivel 54 has piping with similarconnections 54 b-c. The high-pressure conduit 40 has end connections 42,such as 1502 wing type connections or similar, for connection to thewellhead, zipper manifold, etc. It is known in the industry that whenthe assembly described in FIGS. 1A-1B is under high pressure, a waterhammer effect occurs that can cause very damaging vibration through thehigh-pressure conduits 40 a-b.

The subject matter of the present disclosure is directed to overcoming,or at least reducing the effects of, one or more of the problems setforth above.

SUMMARY OF THE DISCLOSURE

Disclosed herein is a manifold skid having at least one single,high-pressure studded or flanged iron connection output, studded orflanged iron connections, and open-faced connections, that are made toAmerican Petroleum Institute (API) 6A standards. Both studded or flangedconnections may be used with the manifold skid of the presentdisclosure, and particularly for the connections of the high-pressureconduit.

Disclosed herein is a manifold skid having at least one single,high-pressure output studded or flanged connection. Iron may be used asthe studded or flanged metal connection but other metals are acceptable,e.g., aluminum, cast, stainless steel, or any metal that can withstandpressure ratings up to about 22500 psi.

A manifold assembly is connectable to pumps that pressurize fluid from alow-pressure source for delivery to a high-pressure destination. Theassembly comprises: a first chassis, a first conduit, and a secondconduit. The first chassis has a length. The first conduit is supportedon the first chassis and is disposed along the length. The first conduithas at least one first inlet and first outlets. The at least one firstinlet is configured to receive the fluid at low-pressure, and the firstoutlets are configured to deliver the fluid at low-pressure to thepumps.

The second conduit is supported on the first chassis and is disposedalong the length adjacent the first conduit. The second conduit hassecond inlets and a second outlet. The second conduit has at least twoconnection blocks and at least two spools connected in line with oneanother along the length of the chassis. Each of the at least twoconnection blocks has one of the second inlets and has at least one portside. Each of the second inlets is configured to receive the fluid athigh-pressure from one of the pumps. The at least two spools areconnected to the port sides of the at least two connection blocks fordelivering the fluid at high pressure to the second outlet of the secondconduit. The second outlet is configured to deliver the fluid athigh-pressure to the destination.

The second conduit can be supported a height above the first conduit.The first conduit can comprise a header in fluid communication with thefirst conduit. The header can have a plurality of the at least one firstinlet. The at least one first outlets can comprise a valve configured toopen and close fluid communication therethrough. The first conduit cancomprise a plurality of the at least one first outlet disposed at spacedintervals along both sides of the length of the first conduit.

The first conduit can comprise at least one port configured to connectin fluid communication with another conduit. The at least one of theconnection blocks can have no elastomeric seal. At least one of theconnection blocks can comply with API 6A standards.

The second conduit can comprise a plurality of the at least oneconnection block and a plurality of the at least one spool. Each of theconnection blocks can have one of the second inlets, and each of theconnection blocks can have one of the port sides connected to one of thespools.

The at least one connection block can comprise two of the at least onesecond inlet on first opposing sides thereof. The two second inlets cancommunicate with one another inside the at least one connection block.

The at least one connection block can comprise two of the at least oneport side on second opposing sides thereof. The two port sides cancommunicate with one another and with the two second inlets inside theat least one connection block.

The second inlet can comprise a bonnet and a ring gasket. The bonnet canbe connected with a plurality of studs and bolts to the port side of theconnection block. The ring gasket can seal the bonnet to the port side.The bonnet can have a female member of a hammer union for coupling witha male member of the hammer union from one of the pumps.

The at least one spool can comprise a flanged end connected with aplurality of studs and bolts to the at least one port side of the atleast one connection block.

The flanged end can define a circumferential groove in a face thereof.The at least one connection block can define a correspondingcircumferential groove in a face thereof circumscribing the at least oneport side, and a gasket can be sandwiched between the circumferentialgrooves.

The assembly can further comprise a third conduit supported on the firstchassis and disposed along the length adjacent the first conduit. Thethird conduit can have at least one third inlet and at least one thirdoutlet. The at least third first inlet can be configured to receive thefluid at low-pressure, and the at least one third outlet can beconfigured to deliver the fluid at low-pressure to at least one of thepumps.

The assembly can further comprise sing a third conduit supported on thefirst chassis and disposed along the length adjacent the second conduit.The third conduit can have at least one third inlet and at least onethird outlet, and the third conduit can have at least one connectionblock and at least one spool. The at least one connection block can havethe at least one third inlet and can have at least one port side. The atleast one third inlet can be configured to receive the fluid athigh-pressure from at least one other of the pumps. The at least onespool can be connected to the at least one port side of the at least oneconnection block for delivering the fluid at high pressure to the atleast one third outlet of the third conduit. The at least one thirdoutlet can be configured to deliver the fluid at high-pressure to thedestination.

The at least second and third outlets of the first and second conduitscan combine to a common outlet. The second and third conduits can runparallel to one another along the length of the first chassis.

The assembly can further comprise a second chassis supporting additionalones of the first and second conduits. The additional one of the firstconduit can be disposed in line with, and connected in fluidcommunication with, the first conduit of the first chassis. Theadditional one of the second conduit can be disposed in line with, andconnected in fluid communication with, the second conduit of the firstchassis.

A manifold assembly is connectable to fracturing pumps that pressurizetreatment fluid from a low-pressure source for delivery to ahigh-pressure destination associated with a wellbore. The assemblycomprises a chassis and at least one conduit. The chassis has a length.The at least one conduit is supported on the chassis and is disposedalong the length.

The at least one conduit has inlets and at least one outlet, and the atleast one conduit has at least two connection blocks and at least twospools. Each of the at least two connection blocks has one of theinlets, and each of the inlets is configured to receive the fluid athigh-pressure from one of the fracturing pumps. Ends of one of thespools interconnects the at least two of the connection blocks in fluidcommunication. The at least one outlet of the at least one conduitcomprises the other of the spools configured to deliver the fluid athigh pressure to the destination associated with the wellbore.

A method of pressurizing fluid from a low-pressure source with pumps fordelivery to a high-pressure destination comprises: receiving the fluidat low pressure from the low-pressure source at at least one first inletof a first conduit; conveying the fluid along a first length of thefirst conduit to a plurality of first outlets spaced along the firstlength of the first conduit and configured to deliver the fluid atlow-pressure to a corresponding one of the pumps; receiving the fluid athigh pressure from the pumps at second inlets in connection blocksinterconnected by spools of a second conduit; and conveying the fluidalong a second length of the second conduit along the connection blocksinterconnected by the spool to a second outlet configured to deliver thefluid at high-pressure to the destination.

The method can further comprise initially blending components of thefluid from the low-pressure source. The method can further comprisepumping the fluid from each of the first outlets with corresponding onesof the pumps; and discharging the pumped fluid at high pressure to oneof the second inlets.

The foregoing summary is not intended to summarize each potentialembodiment or every aspect of the present disclosure.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a perspective view of a typical manifold trailer according tothe prior art as used within the industry.

FIG. 1B is a perspective close view of the trailer in FIG. 1A.

FIG. 2A is a top plan view of a manifold assembly according to anexemplary embodiment of the present disclosure.

FIG. 2B is a side view of the disclosed manifold assembly.

FIG. 2C is a rear view of the disclosed manifold assembly.

FIG. 2D is a front view of the disclosed manifold assembly.

FIG. 3 is a perspective view of an embodiment of a high-pressure conduitflanged manifold fracture delivery system that excludes a low-pressureconduit.

FIGS. 4A-4B are diagrammatic views of intake and outlet arrangements ofa flow assembly for use with the disclosed manifold assembly.

FIG. 5 is a cross-sectional view of a four-way cross-block for use inthe disclosed assembly.

FIG. 6 is a cross-sectional view of a spool for use in the disclosedassembly.

FIG. 7 is a top view of an embodiment of ring gasket for use in thedisclosed assembly.

FIG. 8A is a cross-sectional view of a four-way cross-block, a spool,and a ring gasket mated together for the manifold assembly of thepresent disclosure.

FIG. 8B is a cross-sectional view of a section of the high-pressureconduit.

FIG. 8C is a cross-sectional view of a four-way cross-block, a bonnet, ahammer union, and a ring gasket mated together for the manifold assemblyof the present disclosure.

FIGS. 9A-9B are plan and side views of at least two manifold assembliesof the present disclosure configured together in series.

FIGS. 10A-10C are plan, end, and side views of a header arrangement forthe disclosed manifold assembly.

FIG. 11 is a plan view of another arrangement for the disclosed manifoldassembly.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed in oneembodiment may be beneficially utilized on other embodiments withoutspecific recitation.

DETAILED DESCRIPTION

The subject matter of the present disclosure focuses on a high-pressureside of a manifold assembly used for fracking, treatment, stimulation,or other high-pressure fluid operation. High-pressure in terms of suchoperations can be defined as being up to 22500 psi, with a range ofabout 2000 to 22500 psi. The particular pressures employed for afracking operation depend on the formation being fractured. Should theassembly be used for non-fracturing purposes, the particular pressuresemployed depend on what materials are being processed and for whatpurpose.

Disclosed herein is a manifold assembly designed to deliver fluids for awellhead. The assembly includes a chassis; at least one cross-blockconnected to a spool forming a single low-pressure conduit disposedalong the length of the chassis; at least one high pressure conduitcomprising at least one cross-block connected to a spool, disposed alongthe length of the chassis, the high-pressure outlet terminating at ahigh pressure studded connection to distribute fluids from thehigh-pressure outlet to a wellhead. The high-pressure conduit comprisesat least two blocks and spools coupled together along the length of thechassis.

The cross-blocks and spools are coupled together with studded or flangediron connections and open-faced connections that are manufactured to API6A standards. Each of the cross-blocks and spool connections are coupledto a respective mounting structure, and may be incorporated into thechassis of the manifold assembly.

The manifold assembly 100 can be secured to a variety of surfacesprovided the surface can handle vibrations and can secure the assembly100 in place. For example, the manifold assembly 100 can be secured ontoa skid (which is portable and mobile or fixed and stationary), can besecured onto a pad (cement for example), can mounted on the axle of atrailer, mounted on a flatbed wheel truck, or the like. The assembly 100may be a free-standing skid, or mounted to a trailer, or configured intoa trailer.

In general, the manifold assembly 100 may be used for well fracturingpurposes or other low or high-pressure applications. For example, thedisclosed assembly 100 can be incorporated into a fracturing manifoldskid, although the manifold assembly 100 can be used for applicationsother than fracking. The manifold assembly disclosed may also beconfigured so that the high-pressure outlet studded or flanged ironconnection height from ground level is equal to the inlet of aconnecting downstream assembly. Alternatively, the configuration mayinclude the high-pressure outlet studded or flanged iron connectionheight from ground level being able to be adjusted. Multiple assemblies100 may be connected depending upon needs of the user. It is feasible tohave from 2 to about 4 or more assemblies 100 connected (in series).

Given the overview above, discussion turn to an arrangement of amanifold assembly. FIG. 2A illustrates a top plan view of a manifoldassembly 100 according to the present disclosure. The manifold assembly100 has a chassis 110, which can be a free-standing skid, can be part ofa trailer mounted skid, can be fixedly incorporated into a trailer, orcan be arranged in any combination thereof.

The manifold assembly 100 is connectable to pumps (not shown) thatpressurize fluid from a low-pressure source (not shown) for delivery toa high-pressure destination (not shown). The source can be blender inwhich chemicals, carrier fluid, and proppant or sand are mixed. Thehigh-pressure destination can include one or more fracturing trees,wellheads, other manifold assembly, or the like.

The assembly 100 includes a chassis 110, at least one first conduit 130a-b supported on the chassis 110, and at least one second conduit 140.The conduits 130 a-b, 140 are supported on the chassis 110.

The first conduit 130 a-b is a low-pressure conduit. The first conduit130 a-b has at least one first inlet (e.g., inlet connection 122 on aheader 120) and has first outlets 132. The at least one first inlet 122is configured to receive the fluid at low-pressure from the low-pressuresource, such as the blender (not shown). As noted herein, the fluid canbe a fracturing fluid, a treatment fluid, a slurry, or the like. Thefirst outlets 132 are configured to deliver the fluid at low-pressure tothe pumps (not shown).

The second conduit 140 is a high-pressure conduit. As shown, thehigh-pressure conduit 140 is disposed above the low-pressure conduits130 a-b. It is understood that these conduits 130 a-b, 140 may be inother arrangements. For example, the low-pressure conduits 130 a-b canbe above the high-pressure conduit 140. Moreover, the conduits 130 a-b,140 can be arranged as side by side, or near each other where they arenot directly above or directly below each other.

The high-pressure conduit 140 has at least two connection blocks orcross-blocks 150 and at least two spools 160 connected in line with oneanother along the length of the chassis 110. Each of the connectionblocks 150 has at least one inlet configured to receive the fluid athigh-pressure from at least one of the pumps. Each of the spools 160 isconnected to a port side of a connection block 150 for delivering thefluid at high pressure to an outlet 144 of the high-pressure conduit140. This outlet 144 of the conduit 140 is configured to deliver thefluid at high-pressure to the destination, such as another manifoldassembly, a wellhead, or the like.

As shown, the at least one low-pressure conduit 130 a-b can include twoconduits 130 a-b that run parallel to one another along the length ofthe manifold assembly 100. Incorporated into the low-pressure conduit130 a-b is a low-pressure inlet header 120 having multiple inletconnections 122 (e.g., wing type 1502 connections) to connect to one ormore fluid source (not shown) via flow lines (not shown).

The one or more fluid sources (not shown) can include one or moreblenders, fluid storage tanks, natural water features, or anycombination thereof, although other types of fluid sources can be used.The low-pressure conduit 130 a-b has multiple low-pressure outletconnections 132 (e.g., wing type 1502 connections) having valves. Thevalved connections 132 are disposed at spaced intervals along both sidesof the length of the chassis 110. Each of these valved outletconnections 132 allows for the suction side of a pump (not shown) to becoupled to the low-pressure conduit 130 a-b.

At least some of the valved outlet connections 132 may be coupled to oneor more pumps that pressurize the fluid from the low-pressure conduit130 a-b. As discussed in more detail below, pressurized fluid can thenflow to the high-pressure conduit 140 of the manifold assembly 100.

As shown, the low-pressure conduits 130 a-b has two outlets 134 a-b withvalves at the opposite end of the chassis 110 from the low-pressureinlet manifold 120. These valved outlets 134 a-b allow for a secondmanifold assembly (not shown) or other component to be connected in linewith the present manifold assembly 100. For example, the valved outlets134 a-b can be connected by lines to the inlets 122 of a header 120 onanother assembly. Alternatively, these valved outlets 134 a-b can beconnected directly to the low-pressure conduits 130 a-b on anotherassembly, or the valved outlets 134 a-b may be closed.

As shown in FIG. 2A, the at least one high-pressure conduit 140 can be asingle high-pressure conduit 140 including a series of cross-blocks 150a-d and spools 160 a-d interconnected in series to each other. Each ofthe cross-blocks 150 a-d can be four-way as shown. Although thecross-blocks 150 a-d are described here with a four-way configuration,it is understood that any block having at least two ways and up to sixor more ways for connections may be used.

At one end, the conduit 140 includes a first four-way cross-block 150 athat has one port side 152 c closed with a studded blind flange 154. Thefirst four-way cross-block 150 a includes a first spool 160 a that isconnected from an opposing port side 152 d to a second four-waycross-block 150 b, which in turn is connected to another spool 160 b,and so forth. The four-way cross-blocks 150 a-d are attached to thechassis 110 via support members 115 under each cross-block 150 a-d. Thecross-blocks 150 a-d can be removed for serviceability andreconfiguration or as desired by the user, typically per customerrequirements.

The last spool 160 d on the end of the assembly 100 has a singlehigh-pressure output studded or flanged iron connection for the outlet144 of the manifold assembly 100. This outlet 144 can be connected toone or more systems depending on the implementation. In general, thestudded or flanged iron connection 144 can be connected to: one or moresystems at the wellhead (not shown), one or more systems in the wellboreof which the wellhead is the surface termination, one or more systemsdownstream of the wellhead, or one or more other systems associated withthe wellhead.

FIG. 2B is a side view of the manifold assembly 100. The manifoldassembly 100 is made up of the chassis 110. The low-pressure conduits(only 130 b shown) runs along the length of the manifold assembly 100.Incorporated into the low-pressure conduit 130 b is the low-pressureinlet manifold 120 with the multiple inlet connections 122. Thelow-pressure conduit 130 b has the multiple low-pressure outletconnections 132 with valves. These valved connections 132 allows for thesuction side of a pump (not shown) to be coupled to the low-pressureconduit 130 b.

As noted previously, at least a portion of the low-pressure valvedoutlet connections 132 may be coupled to a pump that pressurizes thefluid from the low-pressure conduit 130 b, which pressurizes fluid andthen flows the pressurized fluid to the high-pressure conduit 140 of themanifold assembly 100. The low-pressure conduit 130 b has the valvedconnection 134 b at the opposite end of the low-pressure inlet manifold120 that allows for a second manifold assembly (not shown) or othercomponent to be connected in line with manifold assembly 100.

As again shown in FIG. 2B, the high-pressure conduit 140 is made up ofthe four-way cross-blocks 150 a-d interconnected by the spools 160 a-c.The first cross-block 150 a has one port side 152 c closed with thestudded blind flange 154. The last four-way cross block 150 d has afinal spool 160 d, with a flanged connection for the outlet 144. As usedherein, “made up,” “connected” and “attached” are considered equivalentand interchangeable words.

The four-way cross-blocks 150 a-d are attached to the chassis 110 viathe support members 115, and the cross-blocks 150 a-d can be removed forserviceability and reconfiguration as desired by the user, or forcustomer requirements.

The high pressure studded or flanged iron connection for the outlet 144is generally set at a height H of about 42-in from the ground levelunlike other manifold trailers. This height H can provide for ease ofconnection of the flanged connection 144 to another manifold assembly(100), a wellhead (not shown), or the like. If required or desired, theheight H can be adjusted for a given implementation using a largerchassis, a pad, different length supports members 115, or the like.

FIG. 2C is a rear view of the manifold assembly 100 showing thelow-pressure header 120. As shown, the low-pressure header 120 can haveseveral rows of a number of valved connections 122. Here, there arethree rows having six connections 122 each, but more or fewer rows andconnections 122 can be provided.

During operation, only one row or portion of one row of the valvedconnections 122 may be connected to a source of fluid, while theremaining valved connections 122 may be shut off. As noted previously,the low-pressure header 120 is connected to the low-pressure conduit(130 a-b shown in FIGS. 2A-2B) to allow fluid to flow through to thelow-pressure valved outlet connections (132 shown in FIGS. 2A-2B).

For the high-pressure conduit 140, a studded blind flange 154 on the endcross-block 150 can be removed to connect to another high-pressureconduit from another manifold assembly (not shown). This allows for theability to connect more pumps for a higher flow rate.

FIG. 2D is a front view of the manifold assembly 100 showing thelow-pressure conduits 130 a-b that run along the length of the manifoldassembly 100. At the front end of the low-pressure conduits 130 a-b, thetwo low pressure connections 134 a-b with valves are shown which can beclosed off or can connect to low pressure conduits (not shown) anothermanifold assembly or to other components.

On the last spool 160 d extending from the last cross-block 150 d, thesingle high-pressure output studded or flanged iron connection 144 canbe connected to: (a) one or more systems at the wellhead (not shown),(b) more systems in the wellbore of which the wellhead is the surfacetermination, (c) one or more systems downstream of the wellhead, or (d)one or more other systems associated with the wellhead. For exemplarypurposes, the high pressure studded or flanged iron connection 144 maybe set at the height H of about 42-in from the ground level for ease ofconnection to another manifold assembly or to a wellhead. If required ordesired, the height H can be adjusted, as already indicated.

For illustrative purposes, FIG. 3 is a perspective view of thehigh-pressure conduit 140, shown in isolation from other components ofthe manifold assembly. The pressurized fluid enters the cross-blocks 150a-d via inlet connections 158 on the opposing port sides 152 a-b. Theinlet connections 158 can include bonnets attached to the cross-block150 a-d with studs, nuts, and a non-elastomeric sealing gasket, asdisclosed herein. The bonnet of the inlet 158 can include the femaleconnector 159 of a 1502 hammer wing union connection for connecting witha male connector (not shown) of the connection.

Inside the cross-blocks 150 a-d, flow from the inlet connections 158 onthe opposing port sides 152 a-b cross over to high-pressure, studded orflanged iron connections to the spools 160 a-d connected to the otheropposing port sides 154 c-d, which are either blocked or connect to oneof the spools 160 a-d.

As noted above, the high-pressure conduit 140 includes the cross-blocks150 a-d interconnected by the spools 160 a-c. The cross-blocks 150 a-dcan be attached to the spools 160 a-d via flanged iron studdedconnections 162 that are manufactured to API 6A standards. The lastspool 160 d has a flanged connection 164 for connecting to othercomponents, as noted herein.

Unlike the connections in FIGS. 1A-1B, the high-pressure conduit 140 inFIG. 3 has no elastomers or gaskets. Instead, as described in moredetail below, the conduit 140 utilizes alloy steel ring gaskets andmetal/metal sealing to provide more reliable and robust sealing. Thisresults in a far superior and robust high-pressure conduit.

It is known in the industry that when an assembly such as described inFIGS. 1A-1B is under high pressure, a hammer effect can occur that cancause very damaging vibration through the high-pressure conduits. Theassembly of the present disclosure, however, can reduce issues withvibration by using the combination of cross-blocks 150 a-d and thespools 160 a-d secured to a skid, as disclosed herein.

As described previously, the manifold assembly 100 can include a chassis110, at least one low pressure conduit 130 a-b disposed along a lengthof the chassis, and at least one high pressure conduit 140 above thelow-pressure conduit 130 a-d disposed along the length of the chassis110. In an alternate arrangement, however, the disclosed assembly 100can have a chassis 110 and at least one high-pressure conduit 140 (e.g.,an embodiment excluding the low-pressure conduit(s) 130 a-b). As before,the high-pressure conduit 140 is made up using cross-blocks 150 a-d andspools 160 a-d with studded or flanged iron connections terminating witha studded or flanged iron connection 144 so the assembly 100 be attachedat the height of the wellhead to route the fluid to the well. Lowpressure connections may be provided to the pumps on another assembly100.

FIGS. 4A-4B are diagrammatic views of both low-pressure andhigh-pressure intake and outlet arrangements of a flow assembly 200 foruse with the disclosed manifold 100. The flow assembly includes a numberof pumps 200 a-b, a low-pressure source 210, and a high-pressuredestination 230. For the low-pressure arrangement of FIG. 4A, the inlets122 of the low-pressure manifold 120 are connected to multiple inlethoses or hard piping 212 to connect the manifold assembly 100 to thelow-pressure source 210, which can include a blender 210 and can be partof one or more fluid sources, one or more fluid storage tanks, naturalwater features, or any combination thereof. The blender flow lines 222are connected to the inlet manifold 120 to deliver the fluid through thelow-pressure conduits 130 a-b that run the length of the assembly 110 tothe low-pressure valve connections 132.

The pumps 200 a-b can be arranged along both sides of the assembly 100,and the suction sides of the pumps 200 a-b connect with hard piping orhoses 222 to the valved connections 132 on the low-pressure conduits 130a-b. The suction side of each pump 200 a-b can connect with one or twohard piping or hoses 222 to the provided pair of the valved connections132 at each spaced location.

To accommodate multiple pumps 200 a-b, the valved connections 132 arespaced at intervals along the length of the chassis 110 and have aspacing generally matching the spacing of high-pressure inlets of thehigh-pressure conduit 140, as discussed below. Here, eight pumps 200 a-bare connected to the manifold assembly 100, although more or fewer pumps200 a-b can be used. For example, one or more pumps 200 a-b and anycombination thereof can be employed depending on the desired use andsite parameters.

For the high-pressure arrangement of FIG. 4B, discharge pressure sidesof the pumps 200 a-b each have a high-pressure outlet pump swing 224that connects to an inlet connection 158 of a cross-block 150 a-d on thehigh-pressure conduit 140.

The cross-blocks 150 a-d and the pump swings 224 can be connected toeach other using connections 158, such as a 1502 hammer union connectionincorporated into a studded adapter flange. To accommodate the multiplepumps 200 a-b, the cross-blocks 150 a-d with their connections 158 arespaced at intervals along the length of the chassis 110 and have aspacing generally matching the spacing of low-pressure inlets 132 of thelow-pressure conduits 130 a-b, as discussed above. Accordingly, thespools 160 have a length that spaces out the cross-blocks 150.

At the end of the assembly 100, the output spool 160 d can connect witha flanged connection 164 to the high-pressure destination 230, which canbe another manifold assembly, one or more systems at the wellhead 230,one or more systems in the wellbore of which the wellhead 230 is thesurface termination, one or more systems downstream of the wellhead 230,or one or more other systems associated with the wellhead 230.

In several exemplary embodiments, each of the pumps 200 a-h shown inFIGS. 4A-4B includes, or is part of, a positive displacement pump, areciprocating pump assembly, a pump truck, a truck, a trailer, or anycombination thereof.

FIG. 5 is a cross-sectional view of a cross-block 150, which includes abody 151 having four port sides 152 a-d. Fluid can flow through andcommunicate through ports 155 in the port sides 152 a-b. Ring gaskets(not shown) can be fitted into ring gasket groove 157 in the port sides152 a-d to create a high-pressure, robust seal between other componentsthat are fixedly attached via studded or flanged connections (notshown), as disclosed herein.

The ports 155 on the port sides 152 c-152 d are configured tocommunicate with the in-line flow of the spools (160) for delivery tothe conduit's outlet (164). Therefore, the ports 155 for these portsides 152 c-152 d are preferably defined in line along an axis. Bycontrast, the ports 155 on the orthogonal port sides 152 a-b areconfigured to receive discharge from the pumps. For manufacturingpurposes, these ports 155 on the orthogonal port sides 152 a-b can bealigned as shown. However, these ports 155 on the orthogonal port sides152 a-b can be offset from one another and can be angled differently tothe orthogonal arrangement shown.

FIG. 6 is a cross section view of a spool 160. The spool 160 is made upof a suitable alloy steel or composite which will typically meet API 6Astandards. The spool 160 includes a conduit or tubing 161 with flangedends 162. A central bore 165 allows for fluid to be pumped through thespool 160. Ring grooves 167 are suitably profiled on faces of theflanged ends 162 to receive a ring gasket (not shown) to create ahigh-pressure, robust seal with the matting components. Holes 166 in theflanged ends 162 receive studs (not shown) to bolt the spool 160 to thematting components and to compress the ring gaskets into the ringgrooves 165.

The inner diameter of the bore 165 of the spool's tubing 161 can beconfigured for the pressures, types of flow, and other details relatedto a given implementation. Conventionally, the bore 165 can have adiameter ranging from about 5-in to about 9-in for use in conducingfracturing fluids and slurries of proppant.

FIG. 7 is a top view of a ring gasket 170 for the disclosed manifoldassembly. Preferably, the gasket 170 conforms to API 6A standards and ismade of an alloy steel or suitable composite material.

FIG. 8A is a cross-sectional view of cross-blocks 150 a-b bolted toflanged ends 162 of a spool 160 using studs 180 and bolts 182. Dependingon the pressure and size of the spool 160 and the cross-blocks 150 a-b,there can be up to eight to ten studs 180 used, for example. The studs180 extend from each of the port sides 152 a-d of the cross-blocks 150a-b. The studs 180 on the opposing port sides 152 a-b can connect tobonnets for pump connections as noted herein. The studs 180 on the otheropposing port sides 152 c-d can be connected to the flanged ends 162 ofspools or to a blind flange (not shown), as noted herein.

FIG. 8B is a cross-sectional view detailing the cross-block 150 fixedlyattached to the flanged end 162 of the spool 160. Once the studs 180 andbolts 182 are torqued down, the ring gasket 170 is compressed into theprofiles 157, 167 to create a high-pressure rated and very robust seal.Due to the high-pressure seal, the fluid port 155 on the cross-block 150and the bore 165 of the spool 164 are connected to allow high pressurefluid communication or flow.

FIG. 8C is a cross-sectional view of a four-way cross-block 150, abonnet 159, and a ring gasket 170 mated together for the manifoldassembly of the present disclosure. As noted previously, pressurizedfluid enters the cross-block 150 via an inlet connection 158, such asthe one shown here on a port side 152 a. The inlet connection 158 caninclude a bonnet 159 attached to the cross-block 150 a with studs 180,nuts 182, and the non-elastomeric sealing gasket 170, as disclosedherein. The bonnet 159 of the inlet 158 can include the female connectorof a 1502 hammer wing union connection 190 for connecting with a maleconnector of the connection 190, which communicate with the dischargeside of a pump (not shown).

The female connector includes a tubular protrusion 191 extending on thebonnet 159. The tubular protrusion has external thread 192 and a taperedface 193. The female connector may or may not have an inner secondaryseal 194, such as a lip-type seal. Such a seal 194 can be composed ofNitrile Butadiene Rubber (NBR), Hydrogenated Nitrile Butadiene Rubber(HNBR), Fluoroelastomer (FKM), Polytetrafluoroethylene (PTFE), or thelike and can include metal or composite backup rings. The male connectorincludes a tubular 195 having a nose 196 that fits into the tapered end193 of the female connector. A hammer nut 197 disposed on the male'stubular 195 with a retainer segment 198 then threads to the externalthread 192 on the female's tubular protrusion 191, which cinches up thenose 196 to the tapered end 193 with a metal-to-metal seal. The 1502union connection 190 may be rated to up to 15,000 psi. Other types ofconnections could be used for the inlet 158.

As FIGS. 8A-8C show, the connections of the connection block 150 may notinclude any elastomeric seals. The gaskets 170 used between the spool160 and connection block 150 and used between the inlet bonnet 159 andthe connection block 150 can be metal or a composite material. Thehammer union connection 190 may not include an elastomeric seal 194 onthe female connector 191.

FIGS. 9A-9B illustrate plan and side views of two or more manifoldassemblies 100 a-c configured together in series. (Three assemblies 100a-c are shown here, but more of fewer can be used). The first assembly100 a is a blender skid that connects toward the blender or otherlow-pressure source (not shown). Accordingly, the blender skid 100 a hasthe header 120 with the source connections 122. This blender skid 100 aconnects to the end of an intermediate assembly 100 b, which in turnconnections to a third assembly that connects toward the wellhead orother high-pressure destination (not shown).

Overall, each of the assemblies 100 a-c are similar to those discussedpreviously and include a chassis 110 supporting at least onelow-pressure conduit 130 a-b and at least one high-pressure conduit 140.As before, the low-pressure conduit 130 a-b has the outlet connections132. As before, the high-pressure conduit 140 includes the cross-blocks150 interconnected by the spools 160.

Each of the cross-blocks 150 include connections 158 for connecting tothe discharge side of a pump (not shown), and these connections 158 caninclude valves 159. The assembly of assemblies 100 a-c in FIGS. 9A-9Ccan accommodate the high-pressure and low-pressure connections for up to26 pumps (not shown).

In contrast to the previous arrangements of the header 120, the blenderskid 100 a includes additional header components, piping, and valving.In particular, FIGS. 10A-10C illustrate plan, end, and side views of aheader arrangement for the disclosed manifold assembly, such as theblender skid 100 a from FIGS. 9A-9B.

The header arrangement has an upper header 120 with chambers separatedby interconnecting piping 121 having a valve 123. The header arrangementalso has a lower header 120′ with chambers separated by interconnectingpiping 121′ having a valve 123′. The upper and lower headers 120, 120′are in turn interconnected to one another by piping 127 having valves129.

The upper header 120 connects to a first set of the low-pressureconduits 130 a-b, which each can have a valve 135 and can beinterconnected with each other using an equalizer valve 133 on anequalizer line 131. Similarly, the lower header 120′ connects to asecond set of the low-pressure conduits 130′a-b, which each can have avalve 135′ and can be in interconnected using an equalizer valve 133′ onan equalizer line 131′.

Each of the sets of upper and lower conduits 130 a-b, 130′a-b can haveconnections 132, 132′ for a suction side of a pump. However, as bestshown in the side view of the blender skid 100 a in FIG. 9B, one of thesets (i.e., lower set 130′) can have connections 132′ while the otherset 130 does not. As also shown in FIG. 9B, the one set (lower set 130′)can end in a termination 139, while the other set (130) can connect tothe adjoining conduits of the intermediate skid 100 b.

The header arrangement in FIGS. 10A-10C allows for blocking off orcombining the connections 132, 132′ on the sides of the low-pressureconduit so the fluid can be conveyed downstream to the other assemblies100 b-c. As one example, the upper conduits 130 a-b on the blender skid100 a may not include connections (132) so that these conduits 130 a-bcan instead convey the fluid downstream to the other skid assemblies 100b-c without suction by a pump as the blender skid 100A. Meanwhile, theconnections 132′ on the adjacent lower conduits 130′a-b can allow forisolated connection of suction sides of the pumps to the blender skid100 a. This can ensure that downstream pumps can have sufficientlow-pressure fluid supply.

Additionally, the header arrangement allows for more than one type offluid to be fed to the suctions sides of the pumps. At the header 120,for example, the two sides of the lower conduits 130′a-b can be fed thesame or different fluids, the two sides of the upper conduits 130 a-bcan be fed the same or different fluids, and the upper and lowerconduits 130 a-b, 130′a-b can be fed the same or different fluids. Infact, the blender skid 100 a can receive four different types of fluidfrom fluid sources for separate delivery to the suction sides of variouspumps.

FIG. 11 is a plan view of another arrangement of a manifold assembly 100according to the present disclosure. As noted previously, the manifoldassemblies of the present disclosure can include at least onelow-pressure conduit 130 and at least one high-pressure conduit 140.Previous arrangements included one high-pressure conduit. Thearrangement in FIG. 11 , however, includes two high-pressure conduits140 a-b running along the sides of the chassis 100. Both conduits 140a-c can be configured as before, having cross-blocks 150 and spools 160.

Ultimately, high-pressure flow from the separate conduits 140 a-b can besent to separate destination or can be combined into a common flow usinga flow combiner 240 downstream of the assembly 100. As will beappreciated, such a flow combiner 240 can take many forms and can beconfigured so as to reduce pressure loss and avoid erosion from thehigh-pressure flow.

In an exemplary embodiment with continuing reference to FIGS. 2A to 11 ,the high-pressure conduit connections can have studded or flanged ironconnections and open-faced connections that are manufactured to API 6Astandards. One benefit of using studded or flanged iron connections andopen-faced connections that are manufactured to API 6A standards is thatthere are no elastomer seals as the studded or flanged iron connectionsand open-faced connections utilize a suitable alloy steel ring gasketdesigned to handle very high pressure, while very reliable and robust tohandle the harsh conditions and applications existing with frackingoperations. Studded or flanged iron connections and open-facedconnections that are manufactured to API 6A standards are preinstalled,serviced and inspected before arriving to a location. The manifoldassembly can be preconfigured to a desired user's requirements whichmakes it easier and safer to connect directly to other components onlocation.

Fracture or Frac or Frack or Fracking can refer to pumping of fluidsdown into the earth, shattering or fracturing below the surface, pushingdown or pumping fluid/sand or mixture thereof.

Connections can be integral or non-integral, wherein integral may meanfor each stud there is a bolt secured to meet a specification;non-integral may mean the currently used connection has a wing nut, butit is understood to be such that the nut can easily be removed and hencethe connection is easily removed.

Free-standing skid may refer to a skid that is loaded onto a trailer andmoved to a specific site and then set on the ground. Mounted orconfigured to a trailer may refer an element being mounted or securedonto the trailer and having its own set of wheels for easy transport ofthe skid. Cross-blocks, also referred to as blocks or connection blocks,may refer to a connecting point secured to a spool, and can beconfigured with two, four, or more ways or connection points.

The foregoing description of preferred and other embodiments is notintended to limit or restrict the scope or applicability of theinventive concepts conceived of by the Applicants. It will beappreciated with the benefit of the present disclosure that featuresdescribed above in accordance with any embodiment or aspect of thedisclosed subject matter can be utilized, either alone or incombination, with any other described feature, in any other embodimentor aspect of the disclosed subject matter.

In exchange for disclosing the inventive concepts contained herein, theApplicants desire all patent rights afforded by the appended claims.Therefore, it is intended that the appended claims include allmodifications and alterations to the full extent that they come withinthe scope of the following claims or the equivalents thereof.

What is claimed is:
 1. A manifold assembly connectable to fracturingpumps that pressurize fluid from a low-pressure source for delivery to ahigh-pressure destination, the assembly comprising: a first chassishaving a length; a pair of first conduits supported on the first chassisand disposed along the length, each of the first conduits of the pairhaving a first inlet and having a first outlet, each of the first inletsbeing configured to receive the fluid at low-pressure, each of the firstoutlets being configured to deliver the fluid at low-pressure; a firstvalve interconnected at a point between the pair of the first conduits,the first valve being configured to open and close fluid communicationbetween the pair of the first conduits; and a second conduit supportedon the first chassis and disposed along the length, the second conduithaving at least two second inlets and having a second outlet, each ofthe at least two second inlets being configured to receive the fluid athigh-pressure from one of the fracturing pumps, the second outlet of thesecond conduit being configured to deliver the fluid at high pressure tothe destination.
 2. The assembly of claim 1, further comprising secondvalves each disposed on a corresponding one of the first conduitsbetween the corresponding first inlet and the point interconnected bythe first valve, each of the second valves being configured to open andclose fluid communication in the corresponding first conduit.
 3. Theassembly of claim 1, wherein the first valve is disposed on a lineinterconnected between the pair of the first conduits.
 4. The assemblyof claim 1, further comprising a first header having at least one firstheader inlet configured to receive the fluid at low-pressure, a firstportion of the first header in fluid communication with the first inletof one of the first conduits, a second portion of the first header influid communication with the first inlet of the other of the firstconduits.
 5. The assembly of claim 4, wherein the first portion is afirst chamber of the first header; wherein the second portion is asecond chamber; and wherein a first header valve interconnects the firstand second chambers of the first header together, the first header valvebeing configured to open and close fluid communication between the firstand second chambers.
 6. The assembly of claim 5, further comprising asecond header having at least one second header inlet configured toreceive the fluid at low-pressure, wherein the assembly furthercomprises another pair of first conduits each connected in fluidcommunication with the second header.
 7. The assembly of claim 6,wherein the second header comprises: third and fourth chambers, thethird chamber connected in fluid communication with one of the firstconduits of the other pair, the fourth chamber connected in fluidcommunication with another of the first conduits of the other pair; anda second header valve interconnecting the third and fourth chambers ofthe second header together.
 8. The assembly of claim 7, furthercomprising: a third header valve interconnecting the first chamber ofthe first header and the third chamber of the second header together;and a fourth header valve interconnecting the second chamber of thefirst header and the fourth chamber of the second header together. 9.The assembly of claim 6, further comprising a second valveinterconnecting the other pair of the of the first conduits together,the second valve being configured to open and close fluid communicationbetween the other pair of the first conduits.
 10. The assembly of claim1, wherein the second conduit comprises at least one connection blockand at least one spool connected in fluid communication with oneanother, the at least one connection block having the at least twosecond inlets, the at least one connection block having at least oneport side, the at least one spool connected to the at least one portside and being configured to deliver the fluid at high pressure to thesecond outlet of the second conduit.
 11. The assembly of claim 10,wherein the at least one connection block comprises the at least twosecond inlets on first opposing sides thereof, the at least two secondinlets communicating with one another inside the at least one connectionblock; and wherein the at least one connection block comprises two ofthe at least one port side on second opposing sides thereof, the twoport sides communicating with one another and with the two second inletsinside the at least one connection block.
 12. The assembly of claim 10,wherein each of the second inlets on the at least one connection blockcomprises a bonnet connected with a plurality of studs and bolts to theat least one connection block; and a ring gasket sealing the bonnet tothe at least one connection block, the bonnet having a female member ofa hammer union for coupling with a male member of the hammer union fromthe corresponding one of the pumps.
 13. The assembly of claim 10,wherein the at least one spool comprises a flanged end connected with aplurality of studs and bolts to the at least one port side of the atleast one connection block.
 14. The assembly of claim 13, wherein theflanged end defines a circumferential groove in a face thereof; whereinthe at least one connection block defines a correspondingcircumferential groove in a face thereof circumscribing the at least oneport side; and wherein a gasket is sandwiched between thecircumferential grooves.
 15. The assembly of claim 1, wherein each ofthe first outlets comprises a second valve configured to open and closefluid communication therethrough.
 16. The assembly of claim 1, whereineach of the first conduits of the pair comprises: at least one outletport configured to connect in fluid communication with another conduit.17. The assembly of claim 1, wherein the second conduit comprise a pairof the second conduit supported on the first chassis and disposed alongthe length adjacent one another.
 18. The assembly of claim 17, whereineach of the second conduits of the pair comprises at least oneconnection block and at least one spool, the at least one connectionblock having one of the at least one two second inlets and having atleast one port side, the at least one spool connected to the at leastone port side of the at least one connection block and being configuredto deliver the fluid at high pressure to the destination.
 19. Theassembly of claim 18, wherein the second outlets of the second conduitsof the pair combine to a common outlet.
 20. The assembly of claim 1,further comprising a second chassis supporting additional ones of thefirst conduits and an additional one of the second conduit, theadditional ones of the first conduits disposed in line with, andconnected in fluid communication with, the first conduits of the firstchassis, the additional one of the second conduit disposed in line with,and connected in fluid communication with, the second conduit of thefirst chassis.
 21. A method of pressurizing fluid from a low-pressuresource with one or more fracturing pumps for delivery to a high-pressuredestination, the method comprising: receiving the fluid at low pressurefrom the low-pressure source; controlling communication of the fluid toa pair of first conduits supported on a chassis; controllingcommunication of the fluid between the pair of the first conduits usinga first valve disposed at a point between the first conduits;controlling communication of the fluid from at least one of a pluralityof first outlets spaced along a first length of the first conduits, eachof the first outlets being supported together on the same chassis andbeing configured to deliver the fluid at low-pressure to a correspondingone of the one or more fracturing pumps; receiving the fluid at highpressure from at least one of the one or more fracturing pumps at atleast one of a plurality of second inlets of a second conduit supportedon the chassis, each of the second inlets being supported together onthe same chassis and being configured to receive the fluid athigh-pressure; and conveying the fluid along a second length of thesecond conduit to a second outlet configured to deliver the fluid athigh-pressure to the destination.